Apparatus and method for curled extrudate

ABSTRACT

A shaping assembly for producing a discrete spiral shaped food product includes a die that defines at least one aperture that is centered on an aperture axis. The at least one aperture extends to an aperture exit and allows for the movement of a stream of food mass through the aperture and out the aperture exit. A shaping tool includes at least one slicing blade that is disposed over at least a portion of the aperture exit to slice the stream of food mass into a plurality of food mass portions. A coupling arrangement engages the shaping tool to facilitate rotation of the slicing blade to spin the plurality of food mass portions into a spiral shaped stream of food mass. The slicing blade simultaneously slices and spins the stream of food mass to create the spiral shaped stream of food mass. A crimper is used to cut the spiral shaped stream of food mass into the discrete spiral shaped food products.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. applicationSer. No. 12/978,705 for an APPARATUS AND METHOD FOR CURLED EXTRUDATE,filed Dec. 27, 2010, which is a divisional of U.S. application Ser. No.11/834,362, now U.S. Pat. No. 7,883,735 for an APPARATUS AND METHOD FORCURLED EXTRUDATE, filed Aug. 6, 2007, which claims the benefit of U.S.Provisional Patent Application Ser. No. 60/821,628 for an APPARATUS ANDMETHOD FOR CURLED EXTRUDATE, filed on Aug. 7, 2006, all of which arehereby incorporated by reference in their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to extruded products and more particularly toprocessing a stream of product from an extruder to achieve a desiredshape.

2. Description of the Related Art

Extruders are used in the preparation of various products, includingfood products such as ready-to-eat (“R-T-E”) cereals. Extruders such ascooker extruders can be desirable because a single machine can producelarge quantities of a cooked dough in a short period of time. Suchcooker extruders can be used to prepare cooked dough extrudates whichcan thereafter be formed into individual cereal or snack pieces. Theformation of such pieces may involve puffing the pieces to form finishedpuffed R-T-E cereals. In another variation, the capabilities of theextruder and the characteristics of the cooked cereal dough are suchthat the dough puffs immediately upon being extruded and is cut intoindividual puffed pieces at the die head.

SUMMARY OF THE INVENTION

In summary, the invention is an apparatus and method for producing asubstantially spiral shaped food product. The apparatus includes a diedefining a plurality of apertures disposed in a circle about a center.The apparatus also includes at least one cutting blade disposed forrotation about the center and operable to intermittently pass fullyacross each of the apertures during rotation. The apparatus alsoincludes a plurality of slicing blades arranged for individual rotationabout one of the plurality of apertures. The plurality of slicing bladesare also arranged for continuous extension less than fully across theone aperture. The apparatus also includes a planetary couplingarrangement operably disposed to facilitate reciprocating rotationbetween the at least one cutting blade and the plurality of slicingblades.

The subject invention further provides for a shaping assembly thatproduces a discrete spiral shaped food product. The shaping assemblyincludes a die that defines at least one aperture that is centered on anaperture axis. The at least one aperture extends to an aperture exit andallows for the movement of a stream of food mass through the apertureand out the aperture exit. A shaping tool includes at least one slicingblade that is disposed over at least a portion of the aperture exit toslice the stream of food mass into a plurality of food mass portions. Acoupling arrangement engages the shaping tool to facilitate rotation ofthe slicing blade to spin the plurality of food mass portions into aspiral shaped stream of food mass. The slicing blade simultaneouslyslices and spins the stream of food mass to create the spiral shapedstream of food mass. A crimping apparatus is used to cut the spiralshaped stream of food mass into the discrete spiral shaped foodproducts.

BRIEF DESCRIPTION OF THE DRAWINGS

Applications of the present invention will become apparent to thoseskilled in the art when the following description of an exemplaryembodiment for practicing the invention is read in conjunction with theaccompanying drawings:

FIG. 1 is a schematic view of an exemplary operating embodiment of theinvention;

FIG. 2 is a cross-sectional view of a shaping assembly having a shapingtool according to the exemplary embodiment of the invention;

FIG. 3 is left-hand view of a blade of the shaping tool according theexemplary embodiment of the invention;

FIG. 4 is a front view of the blade shown in FIG. 3;

FIG. 5 is a first perspective view of the exemplary shaping assemblywherein a shaping tool supporting plate has been removed;

FIG. 6 is a second perspective view of the exemplary shaping assemblywith the shaping tool supporting plate;

FIG. 7 is a cross-sectional view of a shaping assembly having a shapingtool according to a second exemplary embodiment of the subjectinvention;

FIG. 8 is a perspective view of a slicing blade according the secondexemplary embodiment of the subject invention;

FIG. 9 is a perspective view of a slicing blade according the secondexemplary embodiment of the subject invention;

FIG. 10 is a first perspective view of a second exemplary shapingassembly wherein a shaping tool supporting plate has been removed;

FIG. 11 is a second perspective view of the second exemplary shapingassembly with the shaping tool supporting plate;

FIG. 12 is a schematic view of a secondary exemplary operatingembodiment of the present invention; and

FIG. 13 is a partial perspective view of the second exemplary shapingassembly showing a spiral shaped stream of food mass being feed to acrimper.

DETAILED DESCRIPTION OF AN EXEMPLARY EMBODIMENT

Referring now to FIG. 1, in an exemplary embodiment of the invention, afood mass 10 is moved through an extruder 12 to a shaping assembly 14and turned into a helically-shaped food product 15. The food mass 10 isworked by one or more screws in the extruder 12. The food mass 10 issubject to relatively high pressure such that water within the food mass10 is superheated. The food mass 10 can be formulated such that theresulting discrete food product 15 is a snack piece or a cereal piece orany other kind of edible item.

Referring now to FIG. 2, in the exemplary embodiment of a shaping tool,the shaping assembly 14 includes a channeling die plate 16 cooperatingwith the extruder 12 and forming one or more exit ports 18. An outlet 20of the extruder 12 opens to a surface 22 of the channeling die plate 16.The food mass 10, still at high pressure, flows along the surface 22 tothe one or more exit ports 18. The food mass 10 moves through a channel24 between the outlet 20 of the extruder 12 and the exit port 18. Thechannel 24 can be defined by the flat surface 22 and a groove formed inthe extruder 12, or by a flat surface of the extruder 12 and a groove inthe surface 22, or by an additional plate disposed between the extruder12 and the channeling die plate 16.

The shaping assembly 14 includes a die that defines at least oneaperture 28 that is centered on an aperture axis 40. The at least oneaperture 28 extends to an aperture exit 32 and allows for the movementof a stream of food mass 10 through the aperture 28 and out the apertureexit 32. While the die may only define a single aperture 28, the die maydefine a plurality of apertures 28 that are arrayed about a spindle axis60, with each of the plurality of apertures 28 being centered on acorresponding aperture axis 40.

In the exemplary embodiment of the invention, the shaping assembly 14includes a shaping tool supporting plate 26 adjacent to the channelingdie plate 16. The plates 16, 26 define apertures 28, 30 aligned and incommunication with one another to define the exit port 18. The aperture30 of the plate 26 narrows with the respect to the aperture 28 prior toan exit 32 of the exit port 18 to increase the pressure of the food mass10.

In an alternative embodiment of the invention, one or more coloringmaterials can be added to the food mass 10 prior to the exit 32 tomodify the visual appearance of the finished food product 15. Also, oneor more substreams of the food mass 10 can be combined to modify thetaste, appearance and/or texture of the finished food product 15. In theexemplary embodiment of the invention, an insert 34 is disposed in theexit port 18 to accommodate the addition of two different colors, afirst color on the outside of the food product immediately emerging fromthe exit 32 and a second color on the inside of the food productimmediately emerging from the exit 32. The insert 34 includes a shaftportion 35 that is centered and extends along the aperture axis 40 oraxis 40 of the exit port 18.

With use of the insert 34, the resultant stream of food mass 10 includesa first food mass that is surrounded by a second food mass as the streamof food mass 10 exits the aperture exit 32. The first and second foodmasses differ from each other by at least one of color, taste andtexture. When two food masses are used, a second extruder 12 a may beused to feed the second food mass to the insert 34. The second extruder12 a may include an outlet 20 a that feeds the second food mass to theinsert 34. The second food mass moves through a channel 24 a between theoutlet 20 a of the extruder 12 a and the insert 34.

The food mass 10 exits high pressure conditions at the exit 32. Theshaping assembly 14 is disposed adjacent the exit 32 and includes ashaping tool 36 at the exit 32 to induce a spiral or helix shape in thefood mass 10 exiting the exit 32. The shaping tool 36 of the exemplaryembodiment of the invention includes a blade 38 extending at leastpartially across the exit 32. The shaping tool 36 rotates about theaperture axis 40 or center axis 40 of the exit 32 as the food mass 10passes out of the exit 32.

In the exemplary embodiment of the invention, the blade 38 extendshalf-way across the exit 32. A free end or cantilevered end 42 of theblade 38 (shown in FIGS. 3 and 4) is disposed in a groove 44 of theshaft portion 35 to reduce the likelihood of deflection of the blade 38.The groove 44 is annular and extends around the axis 40. The exemplaryblade 38 includes a notch 46 shaped to correspond to the shape of thebottom of the groove 44. In one possible alternative embodiment of theinvention, a blade could extend fully across the exit 32 in place of theblade 38 that extends partially across the exit 32.

In an alternative embodiment, the shaping tool 36 includes at least oneslicing blade 38 that is disposed over at least a portion of theaperture exit 32 to slice the stream of food mass 10 into a plurality offood mass portions. The slicing blade 38 simultaneously slices and spinsthe stream of food mass 10 to create the spiral shaped stream of foodmass 11 exiting the aperture exit 32. A slicing blade 38 has a bladethickness t_(b) that extends axially along the aperture axis 40 to slicethe stream of food mass 10 into the plurality of food mass portions asthe stream of food mass 10 exits the aperture exit 32. The thickness ofthe slicing blade 38 allows for the slicing blade 38 to simultaneouslyslice and spin the stream of food mass 10 into the spiral shaped streamof food mass 11 that exits the aperture exit 32. In the preferredembodiment, the slicing blade 38 slices the stream of food mass 10 intoa plurality of equally sized food mass portions. While a single slicingblade 38 may be used, as seen in FIG. 8, a plurality of slicing blades38, as seen in FIG. 9, may be used.

As seen in FIGS. 8 and 9, the shaping tool 36 may include a plateportion 62 that is O-shaped and has an outer plate periphery 66 and aninner plate periphery 68. While the exemplary embodiment the plateportion 66 is O-shaped, the plate portion 66 may be any shape known inthe art. The inner plate periphery 68 defines a plate opening 70 thatoverlies the aperture exit 32. The stream of food mass 10 is fed fromthe aperture exit 32 and through the plate opening 70. The plate portion62 may include at least one support portion 64 that extends outwardlyfrom the outer plate periphery 66. The support portion 64 defines asupport opening 72 that is capable of receiving a securing mechanism,such as a pin or screw, to secure the plate portion 62 to the shapingassembly 14. In the preferred embodiment, the plate portion 62 issecured to a satellite gear 48 such that the plate portion 62 rotateswith the satellite gear 48 in operation.

As seen in FIG. 8, the slicing blade 38 extends across the plate opening70 with the blade thickness t_(b) extending axially along the apertureaxis 40 to slice the axially fed stream of food mass 10 into a pluralityof food mass portions. It should be appreciated that the plurality offood mass portions results from a single rope of stream of food mass 10being sliced by the slicing blade 38 as the stream of food mass 10 isfed through the slicing blade 38. In the preferred embodiment, theplurality of food mass portions are equally sized.

As the plate portion 62 and the slicing blade 38 disposed within theplate opening 70 are rotated, the plurality of food mass portions arespun into the spiral shaped stream of food mass 11. When a plurality ofslicing blades 38 are used, as seen in FIG. 9, the slicing blades 38 maybe spaced equally about the inner plate periphery 68 of the plateportion 62 to slice the stream of food mass 10 into a plurality ofequally sized food mass portions. In this alternative embodiment, theplurality of slicing blades 38 intersect or engage each other at thecenter of the plate opening 70.

The shaping tool 36 is fixed to a satellite gear 48. The shaping tool 36is releasibly fixed to the gear 48 such that the shaping tool 36 can bereplaced as required. The exemplary shaping tool 36 is rotated about theaxis 40 by the cooperation between the satellite gear 48, a primary orsun gear 50, a spindle 52, and a motor 54 (shown in FIG. 5). The motor54 rotates the spindle 52. The spindle 52 and the primary gear 50 arefixed together for concurrent rotation with one another about an axis 60or spindle axis 60. The primary gear 50 and the satellite gear 48 areengaged for reciprocating rotation with respect to one another. Inaddition, the primary gear 50 and the satellite gear 48 may be engagedfor any rotation with respect to one another.

The plates 16 and 26 include a plurality of exit ports similar to exitport 18; the exit ports being arrayed around the axis 60.

The arrangement and operation of the shaping tool 36 results in the foodmass 10 being curled, spiraled, and/or helical shaped downstream of theshaping tool 36. The speed of rotation of the shaping tool 36 about theaxis 40 can be varied to vary the extent or degree of curling. Inanother words, the relative tightness of the helix can be varied byvarying the speed of rotation of the shaping tool 36. Also, the speed atwhich the food mass 10 exits the exit 32 can be varied in combinationwith varying the speed of rotation of the shaping tool 36 to vary thedegree of curling.

The shaping assembly 14 of the exemplary embodiment of the inventionincludes a cutter 56 to separate the stream of the food mass 10 intodiscrete food pieces 15. The cutter 56 can include one or more blades 58rotating about the axis 60. The axis 60 the exemplary embodiment of theinvention is the center axis of the extruder 12 and is spaced from andparallel to the axis 40. The cutter 56 is fixed with respect to the gear50 and the spindle 52 for concurrent rotation. The speed of rotation ofthe cutter 56 about the axis 60 can be varied relative to the speed ofrotation of the shaping tool 36 by modifying the gear teeth, or gearratio, of the gears 48 and 50.

In addition to the cutter 56, a crimping apparatus 74 may be used tosever the discrete spiral shaped food products 15 from the stream offood mass 10. The crimping apparatus 74 may be used to separate thespiral shaped stream of food mass 11 into the discrete spiral shapedfood products 15. That is, the crimping apparatus 74 pinches and cutsthe spiral shaped stream of food mass 11 into the discrete spiral shapedfood product 15. In the exemplary embodiment, the crimping apparatus 74is spaced from the shaping tool. The crimping apparatus is separate anddistinct from the shaping assembly 14.

In the exemplary embodiment, the crimping apparatus 74 includes at leastone receiving port 76 that is in communication with the aperture exit 32of the aperture 28. The receiving port 76 receives the spiral shapedstream of food mass 11 from the shaping tool 36 to separate, pinch orcut the spiral shaped stream of food mass 11 into the discrete spiralshaped food product 15.

While the crimping apparatus 74 may include a single receiving port 76that corresponds to a single aperture exit 32 in the shaping tool 36,the crimping apparatus 74 in the preferred embodiment includes aplurality of receiving ports 76. If a plurality of receiving ports 76are utilized, each one of the plurality of receiving ports 76 is incommunication with one of the aperture exits 32 of the plurality ofapertures 28. That is, each of the receiving ports 76 corresponds to anaperture exit 32 to receive the spiral shaped stream of food mass IIfrom the corresponding aperture 28 and separate this spiral shapedstream of food mass 11 into the discrete spiral shaped food products 15.

In the exemplary embodiment, the crimping apparatus 74 may be anycrimper or cutter known in the art, including, but not limited to acereal crimper,

Thus, a planetary coupling arrangement is defined between the gears 48,50 to facilitate rotation between the cutting blade 58 and the shapingblade 38. Embodiments of the invention can include a plurality ofshaping blades 38 and a plurality of cutting blades 58. The planetarycoupling arrangement allows for a compact arrangement for a plurality offood streams exiting a plurality of exit ports.

The coupling arrangement engages the shaping tool 36 to facilitaterotation of the slicing blade 38 to spin the plurality of food massportions into a spiral shaped stream of food mass 11. The couplingarrangement includes a spindle 52 that is centered on a spindle axis 60.The coupling arrangement engages both the shaping tool and the spindle52 to facilitate rotation between the shaping tool and the spindle 52 asthe spindle 52 is rotated. The spindle 52 may be rotated by a motor. Theprimary gear 50 is centered on the spindle axis 60 and may be fixed tothe spindle 52 to rotate with the spindle 52 about the spindle axis 60.The satellite gear 48 is centered on the aperture axis 40 and engagesthe primary gear 50 to rotate with the primary gear 50 and about theaperture axis 40. When a plurality of apertures 28 are disposed in thedie, a plurality of satellite gears 48 are used. Each of the apertureexits 32 has a satellite gear 48 that is disposed about the aperture 28to rotate a slicing blade 38 secured thereto over the aperture exit 32to slice the stream of food mass 10 into a plurality of food massportions and simultaneously rotate the plurality of food mass portionsto form the spiral shaped food mass 10.

The foregoing invention has been described in accordance with therelevant legal standards, thus the description is exemplary rather thanlimiting in nature. Variations and modifications to the disclosedembodiment may become apparent to those skilled in the art and do comewithin the scope of the invention. Accordingly, the scope of legalprotection afforded this invention can only be determined by studyingthe following claims.

1. A shaping assembly for producing a discrete spiral shaped foodproduct comprising: a die defining at least one aperture centered on anaperture axis and extending to an aperture exit for movement of a streamof food mass through said aperture and out said aperture exit; at leastone shaping tool having at least one slicing blade being disposed overat least a portion of said aperture exit for slicing the stream of foodmass into a plurality of food mass portions; and a coupling arrangementengaging said shaping tool for facilitating rotation of said slicingblade to spin the plurality of food mass portions into a spiral shapedstream of food mass, wherein said at least one slicing bladesimultaneously slices and spins the stream of food mass to create thespiral shaped stream of food mass.
 2. The shaping assembly as set forthin claim 1 wherein said at least one slicing blade has a blade thicknessextending axially along said aperture axis for slicing the stream offood mass into the plurality of food mass portions.
 3. The shapingassembly as set forth in claim 1 wherein said at least one slicing bladeis a plurality of slicing blades.
 4. The shaping assembly as set forthin claim 1 wherein said at least one shaping tool includes a plateportion being O-shaped and having an outer plate periphery and an innerplate periphery that defines a plate opening overlying said at least oneaperture.
 5. The shaping assembly as set forth in claim 4 wherein saidplate portion includes at least one support portion extending outwardlyfrom said outer plate periphery and defines a support opening forreceiving a securing mechanism to secure said plate portion to saidshaping tool.
 6. The shaping assembly as set forth in claim 4 whereinsaid at least one slicing blade extends across said plate opening andhas a blade thickness extending axially along said aperture axis forslicing the stream of food mass into the plurality of food mass portionsand wherein said at least one slicing blade rotates for spinning theplurality of food mass portions into the spiral shaped stream of foodmass.
 7. The shaping assembly as set forth in claim 6 wherein said atleast one slicing blade is a plurality of slicing blades spaced equallyabout said inner plate periphery of said plate portion for slicing thestream of food mass into a plurality of food mass portions.
 8. Theshaping assembly as set forth in claim 7 wherein said plurality ofslicing blades engage each other at the center of said plate portion. 9.The shaping assembly as set forth in claim 1 wherein said die defines aplurality of apertures arrayed about a spindle axis, each of saidapertures being centered on a corresponding aperture axis.
 10. Theshaping assembly as set forth in claim 9 further including a crimpingapparatus having a plurality of receiving ports, each of said receivingports being in communication with said aperture exit of one of saidplurality of apertures for receiving the stream of food mass from saidcorresponding aperture for separating the spiral shaped stream of foodmass into the discrete spiral shaped food product.
 11. The shapingassembly as set forth in claim 1 wherein said coupling arrangementincludes a spindle centered on a spindle axis and wherein said couplingarrangement engages both said shaping tool and said spindle forfacilitating rotation between said shaping tool and said spindle to spinthe plurality of food mass portions into a spiral shaped stream of foodmass.
 12. The shaping assembly as set forth in claim 11 furtherincluding a primary gear centered on said spindle axis and fixed to saidspindle for rotation with said spindle about said spindle axis.
 13. Theshaping assembly as set forth in claim 12 further including a satellitegear centered on said aperture axis and engaging said primary gear forrotation relative to said primary gear and about said aperture axis. 14.The shaping assembly as set forth in claim 13 wherein said shaping toolis fixed to said satellite gear for rotation therewith.
 15. The shapingassembly as set forth in claim 1 further including a crimping apparatusfor separating the spiral shaped stream of food mass into the discretespiral shaped food product.
 16. The shaping assembly as set forth inclaim 15 wherein said crimping apparatus is spaced from said shapingtool.
 17. The shaping assembly as set forth in claim 15 wherein saidcrimping apparatus has at least one receiving port in communication withsaid aperture exit of said at least one aperture for receiving thestream of food mass to separate the spiral shaped stream of food massinto the discrete spiral shaped food product.
 18. The shaping assemblyas set forth in claim 1 wherein said shaping assembly is secured to anextruder for receiving the stream of food mass.
 19. The shaping assemblyas set forth in claim 1 further including a stream of food mass having afirst food mass surrounded by a second food mass as the stream of foodmass exits the aperture exit.
 20. The shaping assembly as set forth inclaim 19 wherein said first and second food masses differ from eachother by at least one of color, taste and texture.
 21. The shapingassembly as set forth in claim 19 further including an insert disposedin said aperture and having a shaft portion extending along saidaperture axis for producing said stream of food mass having said firstfood mass surrounded by said second food mass.